Process for making metal articles.



W. T. HENSLEY.

PROCESS FOR MAKING METAL ARTICLES.

APPLICATION FILED NOV-24.1913.

1,285,996. Patented Nov. 26, 1918.

2 SHEETS-SHEET -1- 44/1 MM fi awn-Mil W. T. HENSLEY.

PROCESS FOR MAKING METAL ARTICLES.

APPLICATION FILED NOV-24. l9l3.

1,285,996. Patented Nov. 26, 1918.

2 SHEETS-SHEET 2.

T TaTns PATENT oTTToT.

WILLIAM T. HENSLEY, OF BOUNDBROOK, NEW JERSEY, ASSIGNOR, BY MESNE ASSIGN- MENTS, TO BOUND BROOK ENGINE & MFG. 00., A CORPORATION OF DELAWARE.

PROCESS FOR MAKING METAL ARTICLES.

Application filed November 24, 1913.

To all whom it may concern:

Be it known that I, lVinLmar T. HnNsLnY, a citizen ofthe United States of America, and resident of Boundbrook, Somerset county, New Jersey, have invented a certain new and useful Improvement in Processes for Making Metal Articles, of which the following is a specification.

My invention relates to the manufacture of sheet metal dynamo and motor frames. For example, and in the construction of a dynamo or motor of this character, the frame or field structure is composed of laminated sheet metal sections, instead of cast-- ings or solid parts. My invention relates more particularly to the process and means by which the sheet metal is converted into frame sections of the required character.

The object of my invention is to provide a simple and highly efiicient method and means for bending and shaping the sheet metal in a manner that will involveas little expense as possible, but which will, at the same time, insure the production of a high grade article, whereby the cost of manufacture is reduced and the quality of the product maintained or even improved, thus insuring as good, and in some ways a better, article than heretofore, in the manufacture of dynamos and motors, and at less cost than was possible under the old practice.

A special object is to provide a process and means for simultaneously shaping and bending all of the several plates or laminae involved in the construction of a single section of the dynamo or motor frame.

It is also an object to provide certain details and features of improvement tending to increase the general efficiency and desirability of the process and means for making dynamo and motor frames or other parts of this particular character.

To the foregoing and other useful ends my invention consists in matters hereafter set forth and claimed.

In the accompanying drawings- Figure 1 is afront elevation of a hydraulic press involving the principles of my -invention, illustrating the method by which the superimposed plates are simultaneously pressed or bent into shape to form a section of a dynamo or motor frame, the said plates being shown assembled together in the form Specification of Letters Patent.

Patented Nov. 26, leis.

Serial No. 802,646.

of a bundle, being stacked one on top of the other, and disposed in position to be pressed downward into the hollow or-stationary lower die by the downward movement of the upper or movable die.

Fig. 2 is an enlarged plan of the stack or bundle of plates, showing the bottom or under side thereof, and illustrating the manner in which the said plates are assembled and held together by bolts located at the middle of the bundle, whereby the end portions of the plates are free to slide or move relatively to each other during the bending operation.

Fig. 3 is a side elevation of the stack or bundle of plates shown in Fig. 2.

Fig. 4 is a view similar to Fig. 3, but illustrating the result of the first bending operation, the opposite ends of the plates having been bent directly upward.

Fig. 5 is a similar View illustrating the results of the second bending operation, the opposite and upwardly bent ends of the bundle having, as a result of this second operation, been deflected or bent toward each other, but leaving certain portions of the outer plate projecting to provide the means for connecting the sections together to form the frame or field of the dynamo or motor.

Fig. 6 is an enlarged detail section on line 66 in Fig. 1.

Fig. 7 is a fragmental view illustrating the use of rivets for fastening the plates together, the upsetting of the rivets being accomplished during the first bending operation.

As thus illustrated, and referring to Fig. 1, it will be seen that the hydraulic machine comprises a lower die A, and an upper die B, the said lower die being suitably mounted on the frame C, and the said upper die being mounted for vertical reciprocation by the hydraulic piston and cylinder indicated at D, and which may be of any suitable, known or approved character. The said lower die is provided with a curved or concave face a, which curve is on line of a circle struck from the axis of the dynamo or motor; and the upper die B is provided with a curved or convex face 6, whereby the two dies are adapted to cooperate in pressing or bending the bundle of lates into the shape shown cylinders, in any suitable manner.

the die B is provided with shoulders or.

beveled surfaces 6 disposed at a similar angle. Thus, andafter the first bending operation is performed, the dies or rams E are adapted to cooperate with the movable die 18 for the purpose of bending the bundle of plates into the shape shown in Fig. 5. it will be understood that the pistons and cylinders indicated at F, and arranged for operating the dies or rams E, may be'of any suitable, known or approved character.

The method of manufacture is as follows:

Sheet or plate metal of the right width is first sheared to the proper length, and the plates 1, 2, 3, 4, 5 and 6 are then laid flatwise together, in the order mentioned. It will be observed that the said plates are of difierent' lengths, and arranged with the shortest plate on top, whereby the ends of the stack or bundle have a stepped formation, when viewed from the side, as shown in Fig. 3. The plate 6 is preferably wider than the other plates, and is provided with portions 7 which are left projecting outwardly in the manner shown in Fig. 4, and-which are not bent upwardly with the ends of the other plates. The end portions 8 of-the plate 6 are, however, of the same width as the other plates. In order to hold the plates in proper relative position, during the bending operation, they are fastened together by bolts 9 at the centerthereof, thus. leaving the end portions of the plates free toslide' or move relatively to each other, which sliding action is a part of the process or method of I forming the laminated metal body, such as the dynamo or motor frame section.-

When thus fastened together, the plates are placed in position, as shown in Fig. 1, and the machine is then operated to cause the upper die or ram B to move downward, the result being that the bundle of plates is bent into the shape and form shown in Fig. 4-. As the end portions of the stack or bundle must be at an angle to each other, in order to form the poles of the dynamo or motor, a second bending operation is then necessary. This is accomplished while the die or ram B remains in its operated or depressed position, and by causing the honzontal, dies or rams E to move toward eachother. During this second operation the beveled surfaces 6 engage the upstanding end portions of the plates, while they are in the condition shown" in Fig. 4, and the continued movement of these two horizontal dies E toward each other then serves to bend the ends of the plate toward each other and against the shoulders I) of the said vertically naeaeee shape shown in Fig. 5, it being observed that p the two end portions of the bundle are practically at right angles to each other, and that the portlons 7 are allowed to adhere to the line of curvature of the plates to form the means by which several dynamo or motor frame sections of this kind are suitably connected together. Of'course, and as shown in Fig.5, the faces or end surfaces 10 of the poles thus formed are then finished by grinding or otherwise, to give each one the proper curvature-that is to say, the end of each pole must be slightly concave, as these are the surfaces which are brought closeto the cylindric outer surface of the armature of the dynamo or motor. In other words, the surfaces 10 are, when finished, concentric with the'curved outer surface 11 of the dynamo or motor frame sections.

After the laminated body or article thus formed has been finished, and is ready for assembling to form the frame of the dynamo or motor, thebolts 9 can be removed, if desired, and re laced by other elements of the machine. I desired. ring bolts can be inserted through the plates, to hold them together, and these ring bolts can be allowed to remain to form necessary elements of the ment for the plates. With this method, the

first bending operation serves not only to bend the plates into the shape shown in Fig.

4, but also to permanently fasten the same together, by the riveting operation just described.

From the foregoing it will be seen that I provide a simple and highly eflicient process and means for converting sheet metal into laminated frame sections for dynamos or motors. The plates are first curved, by suitable bending means, and the ends of the plates are then bent toward each other, an element of the .first bending means being relied upon to make the second bending operation effective. In other words, the second bending operation occurs while the plates are held under restraint by the first bending operation. Thus the superimposed plates or laminae are bent simultaneously, and the result is a laminated frame section which is so tightly pressed and held together that it approximates a substantially solid body. One plate is bent upon the other, throughout the series of laminae, andduring the bendingoperation the plates slide or adjust themselves relatively to each other, and-the result is that the plates when fully bent and shaped are in perfect contact with each other, thus insuring the best results when the section is incorporated in the frame or field of a dynamo or motor.

It will be understood, of course, that the sheet metal employed. may be of any suitable character, but for the purpose described sheet or plate steel is preferred, as by employing material of this kind the product of my invention has the characteristics necessary for use as apart of the field of a dynamo or motor. By employing the method and means herein described and shown, dynamo and motor frames, and similar structures, are produced with much less expense than heretofore, and of a better quality. For example, and as one advantage of my invention, the expense of making castings is avoided, as by my improved method sheet or plate metal is entirely sufiicient for the construction of dynamo and motor frames,

and the handling and use of sheet metal in the manner described involves much less expense than the old method of forming these parts from cast metal.

By making the plates of difi'erent lengths, in the manner shown, the ends thereof are brought approximately even by the last bending operation. This saves metal, as less metal is cut away in finishing the ends of the pole pieces, than would be the case if the plates were all of the same length before bending.

What I claim as my invention is: 1. The process of making a laminated metal body, which comprises the cutting of sheet metal into plates, superimposing the plates in bundle form, compressing and bending the bundle into the desired shape, thereby causing relative movement of said plates, serving to arrange the edges thereof, and finishing said edges flush.

2. The process of making a laminated metal body, which comprises the cutting of sheet metal into plates, superimposing the plates in bundle form, compressing and bending the bundle into the desired shape, thereby causing relative movement of said plates, serving to arrange the edges thereof,

said bending operation including two steps, first the curving of the bundle and the flexing of the two end portions thereof in parallel relation, and second the forcing of said end portions inward until the edges of each portion are approximately even.

3. The process of making a laminated metal body, which comprises the cutting of sheet. metal into plates, superimposing the plates in bundle form, compressing and bending the bundle into the desired shape, thereby causing relative movement of said plates, serving to arrange the edges thereof, said bending o eration being preceded by the fastening 0 said plates together at the plates in bundle form, compressing and bending the bundle into the desired shape,

thereby causing relative movement of said plates, serving to arrange the edges thereof, said bending operation serving also to provide projections for the body, formed from portions of the outermost plate.

6. The process of making a laminated metal body, which comprises the cutting of sheet metal into plates, superimposing the plates in bundle form, compressing and bending the bundle into the desired shape, thereby causing relative movement of said plates, serving to arrange the edges thereof, said plates being of different lengths, and the length increasing toward the outer side of the body, whereby said arrangement of the edges, produced by the bending operation, serves to even said edges at the ends of the body.

7. The process of making a laminated metal body, which comprises the cutting of sheet metal into plates, superimposing the plates in bundle form, compressing and bending the bundle into the desired shape, thereby causing relative movement of said plates, serving to arrange the edges thereof, and finishing said edges flush to provide smooth end surfaces for said body, said plates being of different lengths, and the length increasing toward the outer side of the body, whereby said arrangement of the edges, produced by the bending operation serves to minimize the loss of metal involved in said finishing operation.

8. The process of making a laminated metal body, which comprises the cutting of sheet metal, into plates, superimposing the plates in bundle form, compressing and bending the bundle into the desired shape, thereby causing relative movement of said plates, serving to arrange the edges thereof, said bending operation being accompanied by a riveting together of said plates at the center of the bundle.

9. The process of making a laminated metal body, which comprises the cutting of sheet metal into plates, superimposing the plates in bundle form, compressing and bending the bundle into the desired shape, thereby causing relative movement of said plates,

serving to arrange the edges thereof, said bending operation being accompanied by a fastening together of said plates at the center of the bundle.

10. The process of making a metal article, which comprises the cutting of sheet metal into suitably shaped plates, bending the plates between their ends and then bending the ends toward each other, while the metal is held in place. by the means for causing the first bending operation.

11. The process of making a metal article, which comprises the cutting of sheet metal into suitably shaped plates, bending the plates between their ends, and then bending the ends toward each other, while the metal is held in place by the means for causing the aaeaeee first bending operation, using an element of 12. The process of making a dynamo or motor frame, comprising the cutting of sheet metal into plates, bending a plurality of plates to form segmental unit sections, and then'forming attaching portions on the outer plate of each section for connecting the unit sections together.

Signed by me at East Boundbrook, N. J., this 17th day of November, 1913.

WILLIAM T. HENSLEY. Witnesses J. MEOHLER, G. S. PARRY. 

